Battery separators and related methods

ABSTRACT

Battery separators and methods are disclosed. The battery separator may be used in a lithium battery. The separator may include a microporous membrane laminated to a coated nonwoven. The coating may contain a polymer and optionally, a filler or particles. The methods may include the steps of: unwinding the microporous membrane and the nonwoven, laminating the nonwoven and microporous membrane, and coating the nonwoven before or after lamination.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a Divisional application to U.S. application Ser.No. 17/560,309, filed Dec. 23, 2021, which claims priority to U.S.application Ser. No. 15/238,850, filed Aug. 17, 2016, and issued as U.S.Pat. No. 11,239,532 on Feb. 1, 2022, which claims priority to and thebenefit of U.S. provisional patent application Ser. No. 62/205,805 filedAug. 17, 2015, hereby fully incorporated by reference herein.

FIELD OF THE INVENTION

At least selected embodiments of the present disclosure or invention aredirected to new, improved or optimized separators, composites, batteriesincluding same, and/or related methods. In at least one embodiment, abattery separator includes a microporous membrane having a nonwovenlaminated thereon. The inventive battery separator can also include amicroporous membrane without having a nonwoven laminated thereon. Thebattery separators may be used in a lithium battery or cell, a lithiumion battery, or a lithium secondary battery, battery pack, module,system, device, vehicle, and/or the like. In accordance with at leastcertain embodiments, the present disclosure or invention is directed tonovel or improved battery separators, laminated separators, compositeseparators, coated laminated separators, coated composite separators,lithium battery separators, and/or methods of making such separators,and/or methods of using such separators or batteries including suchseparators. In accordance with at least certain selected embodiments,the present disclosure or invention is directed to novel or improvedlithium battery separators including a microporous membrane laminated toa coated nonwoven, and the coating may contain a polymer and optionally,a filler or particles, and/or to methods including the steps of:unwinding the microporous membrane and the nonwoven, laminating thenonwoven and microporous membrane, and coating the nonwoven before orafter lamination.

BACKGROUND

Battery separators are generally known. Battery separators for lithiumbatteries are also generally known.

A lithium battery typically includes an anode, a cathode, a separatorbetween the anode and cathode, an electrolyte in ionic communicationbetween the anode and the cathode (e.g., the electrolyte may, in somecases, flow through and reside in the separator), and a containerhousing the foregoing components.

The separator is a critical component of the battery. The separator,among other things, keeps the anode and cathode from coming into contact(e.g., from an external force exerted on or through the container andfrom dendrite growth between the electrodes). The separator provideselectrical insulation. Any contact between the electrodes allowselectrons to be transferred directly between the electrodes, which mayresult in an electrical short circuit. The separator is typicallymicroporous and provides a pathway for ions in the electrolyte to flowfrom one electrode to the other during the charge and discharge cyclesof a battery, such as a lithium battery. The separator may play acritical role in the safety and performance of the battery.

As the demand for better batteries increases, the separator will be onecomponent where battery performance enhancement may be obtained.

U.S. Pat. No. 6,881,515, incorporated herein by reference, discloses aseparator for a polymer battery having a microporous membrane coated, onboth sides, with a gel-forming polymer and plasticizer. The gel-formingpolymer may be polyvinylidene fluoride (PVDF) and its copolymers.

U.S. Pat. No. 7,087,343, incorporated herein by reference, discloses abattery separator for a lithium battery having a shutdown microporousmembrane adhesively bonded to a high melt integrity nonwoven.

There is still a need for new or improved battery separators that willimprove the performance and safety of at least certain batteries, suchas, at least certain lithium batteries.

SUMMARY OF THE INVENTION

At least selected embodiments of the present disclosure or invention mayaddress the above needs, issues or concerns, and/or may provide and/orare directed to new, improved or optimized separators, composites,laminates, batteries including same, and/or related methods. In at leastone embodiment, a battery separator includes a microporous membranehaving a nonwoven laminated thereon. The inventive battery separator canalso include a microporous membrane without having a nonwoven laminatedthereon. The battery separators may be used in a lithium battery orcell, a lithium ion battery, or a lithium secondary battery, batterypack, module, system, device, vehicle, and/or the like.

In accordance with at least certain embodiments, the present disclosureor invention is directed to novel or improved battery separators,laminated separators, composite separators, coated laminated separators,coated composite separators, lithium battery separators, and/or methodsof making such separators, and/or methods of using such separators orbatteries including such separators. In accordance with at least certainselected embodiments, the present disclosure or invention is directed tonovel or improved lithium battery separators including a microporousmembrane laminated to a coated nonwoven, and the coating may contain apolymer and optionally, a filler or particles, and/or to methodsincluding the steps of: unwinding the microporous membrane and thenonwoven, laminating the nonwoven and microporous membrane, and coatingthe nonwoven before or after lamination.

At least selected embodiments of the present invention are directed tonew, improved or optimized separators, composites, batteries includingsame, and/or related methods. In one embodiment, a battery separatorincludes a microporous membrane having a nonwoven laminated thereon. Theinventive battery separator can also include a microporous membranewithout having a nonwoven laminated thereon. The battery separators maybe used in a lithium battery or cell, a lithium ion battery, or alithium secondary battery, battery pack, module, system, device,vehicle, or the like. In accordance with at least selected embodiments,the present disclosure or invention is directed to novel or improvedbattery separators, laminated separators, composite separators, coatedlaminated separators, coated composite separators, lithium batteryseparators, and/or methods of making such separators, and/or methods ofusing such separators or batteries including such separators. Inaccordance with at least certain embodiments, the present disclosure orinvention is directed to novel or improved lithium battery separatorsincluding a microporous membrane laminated to a coated nonwoven, thecoating may contain a polymer and optionally, a filler or particles,and/or to methods including the steps of: unwinding the microporousmembrane and the nonwoven, laminating the nonwoven and microporousmembrane, and coating the nonwoven before or after lamination.

In accordance with at least possibly preferred embodiments, aspects orobjects, the inventive separator may result in an improved batteryseparator by, among other things, improving the puncture strength,reducing splittiness (e.g., increase cross machine strength), improvinghigh temperature melt integrity, improving tensile strengths (in boththe machine and cross machine directions), and/or having a shutdownfunction.

DESCRIPTION OF THE DRAWINGS

For the purpose of illustrating at least certain exemplary embodimentsor aspects of the invention, there is shown in the drawings a form thatis presently preferred; it being understood, however, that thisinvention is not limited to the precise arrangements andinstrumentalities shown.

FIG. 1 is a schematic illustration of a cross-section of an embodimentof the instant invention, which is a one sided lamination of components(nonwoven and membrane).

FIG. 2 is a schematic illustration of a cross-section of anotherembodiment of the instant invention which is a two sided lamination ofcomponents (nonwovens and membrane).

FIG. 3 is a schematic illustration of a cross-section of anotherembodiment of the instant invention involving one-side coated layers orcomponents.

FIG. 4 is a schematic illustration of a cross-section of anotherembodiment of the instant invention involving two-sided coated layers orcomponents.

FIG. 5 is a schematic illustration of a cross-section of anotherembodiment of the instant invention involving two-sided membranes andcoatings.

FIG. 6 is a cross-sectional view of a fiber taken generally alongsection lines 6-6 in FIG. 1 .

FIG. 7 is a cross-sectional view of a side-by-side bicomponent fiber.

FIG. 8 is a cross-sectional view of an island-in-the-sea bicomponentfiber.

FIG. 9 is a schematic illustration of a cross-section of anotherembodiment of the instant invention involving a one-side coatedmembrane.

FIG. 10 is a schematic illustration of a cross-section of anotherembodiment of the instant invention involving a two-sided coatedmembrane.

FIG. 11 is a schematic illustration of a cross-section of anotherembodiment of the instant invention involving a one-side coatedmembrane.

FIG. 12 is a schematic illustration of a cross-section of anotherembodiment of the instant invention involving a two-sided coatedmembrane.

FIG. 13 is a schematic illustration of an embodiment of a method formaking a single or double side laminated coated battery separator.

FIG. 14 is a schematic illustration of another embodiment of a methodfor making a single or double side laminated coated battery separator.

FIG. 15 is a schematic illustration of another embodiment of a methodfor making a single or double side coated battery separator.

FIG. 16 is a schematic illustration of another embodiment of a methodfor making a single or double side coated battery separator.

DETAILED DISCUSSION OF THE INVENTION

At least selected embodiments of the present disclosure or invention aredirected to new, improved or optimized separators, composites, batteriesincluding same, and/or related methods. In at least one embodiment, abattery separator includes a microporous membrane having a nonwovenlaminated thereon. The inventive battery separator can also include amicroporous membrane without having a nonwoven laminated thereon. Thebattery separators may be used in a lithium battery or cell, a lithiumion battery, or a lithium secondary battery, battery pack, module,system, device, vehicle, and/or the like. In accordance with at leastcertain embodiments, the present disclosure or invention is directed tonovel or improved battery separators, laminated separators, compositeseparators, coated laminated separators, coated composite separators,lithium battery separators, and/or methods of making such separators,and/or methods of using such separators or batteries including suchseparators. In accordance with at least certain selected embodiments,the present disclosure or invention is directed to novel or improvedlithium battery separators including a microporous membrane laminated toa coated nonwoven, and the coating may contain a polymer and optionally,a filler or particles, and/or to methods including the steps of:unwinding the microporous membrane and the nonwoven, laminating thenonwoven and microporous membrane, and coating the nonwoven before orafter lamination.

At least selected embodiments of the present invention are directed tonew, improved or optimized separators, composites, batteries includingsame, and/or related methods. In one embodiment, a battery separatorincludes a microporous membrane having a nonwoven laminated thereon. Theinventive battery separator can also include a microporous membranewithout having a nonwoven laminated thereon. The battery separators maybe used in a lithium battery or cell, a lithium ion battery, or alithium secondary battery, battery pack, module, system, device,vehicle, or the like. In accordance with at least selected embodiments,the present disclosure or invention is directed to novel or improvedbattery separators, laminated separators, composite separators, coatedlaminated separators, coated composite separators, lithium batteryseparators, and/or methods of making such separators, and/or methods ofusing such separators or batteries including such separators. Inaccordance with at least certain embodiments, the present disclosure orinvention is directed to novel or improved lithium battery separatorsincluding a microporous membrane laminated to a coated nonwoven, thecoating may contain a polymer and optionally, a filler or particles,and/or to methods including the steps of: unwinding the microporousmembrane and the nonwoven, laminating the nonwoven and microporousmembrane, and coating the nonwoven before or after lamination.

In at least one embodiment, the inventive separator may result in animproved battery separator by, among other things, improving thepuncture strength, reducing splittiness (e.g., increase cross machinestrength), improving high temperature melt integrity, improving tensilestrengths (in both the machine and cross machine directions), and/orhaving a shutdown function.

In FIG. 1 , there is shown a first exemplary embodiment of the inventionas a separator 8 that includes a coating layer 10 adhered to the surfaceof a nonwoven 12 which is thermally laminated forming an interfacialbond 15, to a microporous membrane 14. In this embodiment, the coatinglayer 10 is adhered to the surface of nonwoven material or layer 12.This coating can be fully or partially impregnated into the nonwoven 12.

In FIG. 2 , there is shown a second exemplary embodiment of theinvention as a separator 9 that includes respective coating layers 10adhered to the surface of respective nonwoven layers 12 which arethermally laminated to respective sides of a microporous membrane 14,forming interfacial bonds 15.

In FIG. 3 , there is shown a third exemplary embodiment of the inventionas a separator 11 that includes a coating layer 10 adhered to thesurface of nonwoven 12 which is laminated or bonded to one side of acoating layer 16 adhered to the surface of a microporous membrane 14.

In FIG. 4 , there is shown a fourth exemplary embodiment of theinvention as a separator 13 that includes respective coating layers 10adhered to the surface of respective nonwovens 12 which are laminated torespective coating layers 16 on both sides or surfaces of a microporousmembrane 14.

In FIG. 5 , there is shown a fifth exemplary embodiment of the inventionas a separator 25 that includes respective coating layers 10 adhered toboth surfaces of a nonwoven 12 and which are double side laminated torespective microporous membranes 14 each having a respective coatinglayer 16 adhered to a respective side or surface of a respectivemicroporous membrane 14.

The nonwoven component, material or layer 12 may be made of natural,synthetic, polymeric, and/or glass fibers. In one embodiment, the fiberpolymer may be selected from the group of: polyolefin, polyester,fluoro-polymer, e.g., PVDF, polyamide (e.g., nylon), polyaramid (KEVLAR,NOMEX), acrylic, PVC, or other polymers. In another embodiment, thepolyester may be selected from the group consisting of polyethyleneterephthalate (PET), polybutylene terephthalate (PBT), polyethylenenaphthalate (PEN), polytrimethylene terephthalate (PTT), co-polymers ofthe foregoing, and blends of the foregoing.

The nonwoven 12 may be a carded nonwoven, a needle-punched nonwoven, anair-laid nonwoven, a wet-laid nonwoven, a spunlaced (hydroentangled)nonwoven, a spunbonded nonwoven, a melt-spun nonwoven, an electro-spunnonwoven, an electro-blown nonwoven, a meltblown nonwoven, andcombinations thereof. The nonwoven may be made of staple fibers, and/orcontinuous filaments. In one embodiment, the nonwoven may have athickness of less than 1 mil (25.4 microns). In another embodiment, thenonwoven may have a thickness of less than 0.5 mil (12.7 microns). Inyet another embodiment, the nonwoven may have a thickness of less than0.2 mil (5 microns).

The fibers comprising the nonwoven 12 may have a diameter less thanabout 10 microns. In another embodiment, the diameter of the fibers maybe less than about 1 micron. In another embodiment, the diameter of thefibers may be less than about 0.1 microns. In another embodiment, thediameter of the fibers may be less than about 0.01 microns. In anotherembodiment, the diameter of the fibers may be less than about 0.001microns.

The membrane 14 and/or nonwoven 12 may further include one or morecoatings 10 and/or 16. The coating 10 or 16 may cover the surface of thenonwoven or the coating may cover the surface of the nonwoven andpartially, or to a large degree, impregnate into the open or porousstructure of the nonwoven. The coating may partially cover or completelycover the surface of the nonwoven fibers comprising the nonwoven.

The coating 10 or 16 may be made of a natural, synthetic or polymericmaterial and in one embodiment, be selected from the polymer groupconsisting of polyethylene, polypropylene, PET, polyvinylidene fluoride(PVDF), polytetrafluoroethylene (PTFE), polyvinylidene chloride,acrylic, polychloride (PVC), polyacrylonitrile (PAN),polymethylmethacrylate (PMMA), polyamide, styrenebutadiene copolymer,ethylene styrene copolymer, styrene-isoprene copolymers,ethylene-acrylic acid copolymer, polydiene, polyalkane polyvinyl ketone,polyvinyl halide, polyvinyl nitrile, polyvinyl ester, polystyrene,polyphenylene, polyoxide, polycarbonate, polyester, polyanhydride,polyurethane, polysulfonate, polysulfide, polysulfone, co-polymersthereof, and blends containing the foregoing. In another embodiment, thepolymeric material may be selected from the group consisting ofpolyvinylidene fluoride (PVDF), co-polymers thereof, and blendscontaining the foregoing. In yet another embodiment, one particularlyuseful polymer is the polyvinylidene fluoride (PVDF)-hexafluoropropylene(PVDF:HFP) co-polymer and/or polyvinylchloride and mixtures thereof.

The coating 10 or 16 may include natural, synthetic, polymer, glass, orceramic filler or particles. The filler may be blended into the coatingbefore application to the nonwoven.

The filler may be an inert, thermally stable particle. The filler may bea ceramic particle selected from the group consisting of silicon dioxide(SiO₂), aluminum oxide (Al₂O₃), calcium carbonate (CaCO₃), titaniumdioxide (TiO₂), SiS₂, SiPO₄, or glass and mixtures thereof. In anotherembodiment, the filler may be a ceramic particle selected from the groupconsisting of silicon dioxide (SiO₂), aluminum oxide (Al₂O₃), calciumcarbonate (CaCO₃), titanium dioxide (TiO₂), and mixtures thereof. In yetanother embodiment, the filler may be a ceramic particle selected fromthe group consisting of silicon dioxide (SiO₂), aluminum oxide (Al₂O₃),calcium carbonate (CaCO₃), and mixtures thereof.

The filler may have an average particle size in the range of about 0.001micron to about 2 microns. In another embodiment, the average particlesize of the filler may be in a range of about 0.01 micron to 2 microns.U.S. Pat. No. 6,432,586, which is incorporated herein by reference inits entirety, discloses various ceramic-coated separators. Additionally,U.S. Patent Publication No. 2014/0045033, which is also incorporatedherein by reference in its entirety, discloses various ceramicparticle-containing polymeric coatings for microporous battery separatormembranes.

Ceramic coatings may include one or more polymeric binders, one or moretypes of inorganic ceramic particles and a water based (aqueous) or anon-aqueous solvent. Such coatings may be applied using varioustechnologies such as, but not limited to, dip coating, knife, gravure,curtain, spray, etc. Furthermore, various known ceramicparticle-containing polymeric coatings may be applied at varyingthicknesses, such as a thickness of, for example, 2 to 6 microns ontoone or both sides of a microporous battery separator, nonwoven layer,separator membrane, or combinations thereof.

The nonwoven component, material or layer 12 may be made of bicomponent(hetero-fil) fibers or non-bicomponent fibers. The bicomponent fiber maybe selected from the group consisting of sheath-core fibers 18 (see FIG.6 —core 20 and sheath 22), side-by-side fibers 18′ (see FIG. 7 —one side18′a and the other side 18′b), island-in-the-sea fibers 18″ (see FIG. 8—islands 18″a and sea 18″b) and combinations thereof. The bicomponentfiber may have a low melt temperature component and a high melttemperature component. The low melt component may have a melttemperature less than the high melt temperature component. In oneembodiment, the low melt temperature component may be a polyolefin. Inone embodiment, the polyolefin may be selected from the group consistingof: polyethylene (PE), polypropylene (PP), polymethylpentene (PMP),polybutene (PB), co-polymers of the foregoing, and blends of theforegoing. The high melt temperature component may be selected from thegroup consisting of: polyvinylidene fluoride (PVDF),polytetrafluoroethylene (PTFE), polyvinylidene chloride, acrylic,polychloride (PVC), polyacrylonitrile (PAN), polymethylmethacrylate(PMMA), polyamide, styrenebutadiene copolymer, ethylene styrenecopolymer, styrene-isoprene copolymers, ethylene-acrylic acid copolymer,polydiene, polyalkane polyvinyl ketone, polyvinyl halide, polyvinylnitrile, polyvinyl ester, polystyrene, polyphenylene, polyoxide,polycarbonate, polyester, polyanhydride, polyurethane, polysulfonate,polysulfide, polysulfone, co-polymers thereof, and blends containing theforegoing. In another embodiment, the bicomponent fiber may have apolyolefin sheath and a core being made of a polymer selected from thegroup consisting of: polyester, polyamide (eg, nylon), fluoro polymer(eg TEFLON), aramid (KEVLAR, NOMEX), liquid crystal polymer (VECTRAN),polybenzimidazole (PBI), polybenzobisoxazole (PBO). In yet anotherembodiment, the bicomponent fiber may have a polyethylene sheath and acore being made of a polymer selected from the group consisting of:polyester, polyamide (eg, nylon), fluoro polymer (eg TEFLON), aramid(KEVLAR, NOMEX), liquid crystal polymer (VECTRAN), polybenzimidazole(PBI), polybenzobisoxazole (PBO). In yet another embodiment, thebicomponent fiber may have a polyolefin sheath and a polyester core. Inyet another embodiment, the bicomponent fiber may have a polyethylenesheath and a polyethylene terephthalate (PET) core.

The separators or separator components or membranes 8, 9, 11, 13, and 25in FIGS. 1, 2, 3, 4, and 5 , respectively, may be microporous and mayhave a porosity in the range of about 20-95%.

The microporous membrane or layer 14 may have an average pore size inthe range of about 0.02 to about 2 microns. The microporous membrane 14may have an average pore size in the range of about 0.04 to about 0.5micron.

The additional exemplary embodiments of the invention depicted in FIGS.9, 10, 11, and 12 may not contain a nonwoven layer or component 12 butmay include one or more coatings 10 and/or 16 on one or both sides of amembrane 14. The membrane 14 and/or the coatings 10 and/or 16 mayinclude one or more fibers, fillers or particles. The filler may beblended into the coating before application to the microporous membrane14. The filler may be an inert, thermally stable fiber or particle. Thefiller may be a ceramic particle selected from the group consisting ofsilicon dioxide (SiO₂), aluminum oxide (Al₂O₃), calcium carbonate(CaCO₃), titanium dioxide (TiO₂), SiS₂, SiPO₄, or glass and mixturesthereof. In another embodiment, the filler may be a ceramic particleselected from the group consisting of silicon dioxide (SiO₂), aluminumoxide (Al₂O₃), calcium carbonate (CaCO₃), titanium dioxide (TiO₂), andmixtures thereof. In yet another embodiment, the filler may be a ceramicparticle selected from the group consisting of silicon dioxide (SiO₂),aluminum oxide (Al₂O₃), calcium carbonate (CaCO₃), and mixtures thereof.

The filler may have an average particle size in the range of about 0.001micron to about 2 microns. In another embodiment, the average particlesize of the filler may be in a range of about 0.01 micron to about 2microns.

The microporous membrane 14 may have an ASTM Gurley Number in the rangeof about 37 to 150 sec. The microporous membrane may have a GurleyNumber in the range of about 30 to 80 sec. ASTM Gurley Number refers tothe time it takes for 10 cc of air at 12.2 inches of water to passthrough one square inch of membrane.

The microporous membrane 14 may have any number of plies. In someembodiments, the microporous membrane has a single ply. In the case of asingle ply, the single ply may be made of a polyolefin. The polyolefinmay be selected from the group consisting of: polyethylene (PE),polypropylene (PP), polymethylpetene (PMP), polybutene (PB), co-polymersof the foregoing, and blends of the foregoing. In another embodiment,the polyolefin may be selected from the group consisting of:polyethylene (PE), polypropylene (PP), co-polymers of the foregoing, andblends of the foregoing. In yet another embodiment, the polyolefin maybe selected from the group consisting of: polyethylene (PE), co-polymersof the foregoing, and blends of the foregoing. In yet anotherembodiment, the polyolefin of the single ply may be polyethylene (PE).

The microporous membrane 14 may have multiple plies. For example, themicroporous membrane may have two plies. In this case, each ply may bemade of a different polymer. One ply may be made of a polyolefin. Thepolyolefin may be selected from the group consisting of: polyethylene(PE), polypropylene (PP), polymethylpetene (PMP), polybutene (PB),co-polymers of the foregoing, and blends of the foregoing. In anotherembodiment, the polyolefin may be selected from the group consisting of:polyethylene (PE), co-polymers of the foregoing, and blends of theforegoing. In yet another embodiment, the polyolefin may be polyethylene(PE). The other ply may be made of a polyolefin. The polyolefin may beselected from the group consisting of: polyethylene (PE), polypropylene(PP), polymethylpetene (PMP), polybutene (PB), co-polymers of theforegoing, and blends of the foregoing. In another embodiment, thepolyolefin may be selected from the group consisting of: polypropylene(PP), co-polymers of the foregoing, and blends of the foregoing. In yetanother embodiment, the polyolefin may be polypropylene (PP). In yetanother embodiment, one ply may be made of a polyethylene-based polymerand the other ply may be made of a polypropylene-based polymer.

The microporous membrane may have three or more plies. At least one plymay be made of a different polymer. And, at least two plies may be madeof a same polymer. The outer plies may be made of the same polymer andthe inner ply may be made of a different polymer. The same polymer maybe a polyolefin. The polyolefin may be selected from the groupconsisting of: polyethylene (PE), polypropylene (PP), polymethylpetene(PMP), polybutene (PB), co-polymers of the foregoing, and blends of theforegoing. In another embodiment, the polyolefin may be selected fromthe group consisting of: polypropylene (PP), co-polymers of theforegoing, and blends of the foregoing. In yet another embodiment, thepolyolefin being polypropylene (PP). The different polymer may be apolyolefin. The polyolefin may be selected from the group consisting of:polyethylene (PE), polypropylene (PP), polymethylpentene (PMP),polybutene (PB), co-polymers of the foregoing, and blends of theforegoing. In another embodiment, the polyolefin may be selected fromthe group consisting of: polyethylene (PE), co-polymers of theforegoing, and blends of the foregoing. In yet another embodiment, thepolyolefin may be polyethylene (PE). The plies may be layered aspolypropylene (PP)/polyethylene (PE)/polypropylene (PP) or polyethylene(PE)/polypropylene (PP)/polyethylene (PE).

An exemplary first method of making the laminated or bonded embodimentof the battery separator is illustrated in FIG. 13 . Lamination providesthe following benefits to the manufacture of the separator: uniformityor thickness, adhesion of the nonwoven to the microporous membrane,condensement of the nonwoven and microporous membrane and the creationof the interfacial layer 15 (see FIGS. 1 and 2 ).

In FIG. 13 , the first exemplary embodiment of the method to makeseparator 8 shows a method 100 of making a laminated battery separatormay include the steps of: 1) unwinding a nonwoven 102, 2) unwinding amicroporous membrane 104, 3) coating the nonwoven with a coatingmaterial 106, and 4) laminating the coated nonwoven to the microporousmembrane 104 to form a composite or laminate 110. Additionally, themethod may include the optional steps of forming a roll of laminatedseparator 112 and slitting the laminated separator 112 into narrowerwidths, and winding the slits or slit separators 114.

With reference again to FIG. 13 , a second exemplary embodiment of amethod to make a laminated battery separator may include the stepsof: 1) unwinding a first and second nonwoven 102, 2) unwinding amicroporous membrane 104, 3) coating the nonwovens with a coatingmaterial 106, and 4) laminating a respective coated nonwoven to eachside of the microporous membrane 104 to form a laminate 110 to makeseparator 9.

Laminating may be performed by calendering. Calendering is performed bypassing the nonwoven and the microporous membrane through the nip of tworolls or rollers such as two heated rollers, where heat and pressure areapplied so that the adjacent surfaces (polymers) of the nonwoven andmicroporous membrane are fused at the interfacial bond 15 of FIGS. 1 and2 . Additionally, the method may include the optional steps of slittingthe laminated separator 112 into narrower widths, and winding the slitseparators 114. The coating material may contain a filler or particles.The coating may be applied by spraying, dipping, contact coating,gravure-type coating and/or brushing. The coating or coatings may beapplied to one or both sides of the nonwoven, or to the side on themicroporous membrane that contacts the nonwoven, or on both sides of themicroporous membrane, or to one or both sides of the nonwoven and/ormembrane.

In FIG. 14 , another exemplary embodiment of the method to make acoated, laminated battery separator is illustrated. This method 200includes the steps of: 1) unwinding a microporous membrane 204, 2)unwinding a nonwoven material 202, 3) coating the nonwoven 202 withcoating material 206, 4) coating microporous membrane 204 with a coatingmaterial 208, 5) laminating coated microporous membrane 204 and coatednonwoven 202 to make laminated or bonded component or laminate 210 whichcan be separator or membrane 11 (see FIG. 3 ). Additionally, respectivenonwovens 202 coated with 206 can be laminated to both sides ofmicroporous membrane 204 coated with 208 to make laminated membrane 210which can be separator or membrane 13 (see FIG. 4 ). Additionally,nonwoven 202 coated on both sides with coating 206 can be laminated onboth sides to respective coated membranes 204,208 to make laminatedmembrane 210 which can be separator or membrane 25 (see FIG. 5 ). Thecoatings may be applied by spraying, dipping, contact coating,gravure-type coating and/or brushing. Additionally, the method mayinclude the optional steps of slitting the coated separator 212 intonarrower widths, and winding the slit separators 214.

In FIG. 15 , another exemplary embodiment of the method to make a coatedbattery separator is illustrated. This method 300 includes the stepsof: 1) unwinding a microporous membrane 304, 2) coating microporousmembrane 304 with a coating material 308, 3) coating coated material 304with coating 306 to make coated membrane 310 which can be separator ormembrane 17. (See FIG. 9). Additionally, membrane 304 can be coated onboth sides with coating 308 and then coated with coating material 306 tomake coated membrane 310 which can be separator or membrane 19. (SeeFIG. 10 ). The coatings may be applied by spraying, dipping, contactcoating, gravure-type coating, and/or brushing. Additionally, the methodmay include the optional steps of slitting the coated material orseparator 312 into narrower widths, and winding the slit separators 314.

In FIG. 16 , another exemplary embodiment of the method to make a coatedbattery separator is illustrated. This method 400 includes the stepsof: 1) unwinding a microporous membrane 404, 2) coating microporousmembrane 404 with a coating material 406 to make coated membrane 410which can be separator or membrane 21. (See FIG. 11 ) Additionally,membrane 404 can be coated on both sides with coating 406 to make coatedmembrane 410 which can be separator or membrane 23. (See FIG. 12 ) Thecoatings may be applied by spraying, dipping, contact coating,gravure-type coating and/or brushing. Additionally, the method mayinclude the optional steps of slitting the coated separator 412 intonarrower widths, and winding the slit separators 414.

Battery separators and methods are disclosed. The battery separator maybe used in a lithium battery. The separator may include a microporousmembrane laminated to a coated nonwoven. The coating may contain apolymer and optionally, a filler or particles. The methods may includethe steps of: unwinding the microporous membrane and the nonwoven,laminating the nonwoven and microporous membrane, and coating thenonwoven before and/or after lamination.

At least selected embodiments, aspects or objects of the presentdisclosure or invention are directed to and/or may provide new, improvedor optimized separators, composites, batteries including same, and/orrelated methods. In at least one embodiment, a battery separatorincludes a microporous membrane having a nonwoven laminated thereon. Theinventive battery separator can also include a microporous membranewithout having a nonwoven laminated thereon. The battery separators maybe used in a lithium battery or cell, a lithium ion battery, or alithium secondary battery, battery pack, module, system, device,vehicle, and/or the like. In accordance with at least certainembodiments, the present disclosure or invention is directed to novel orimproved battery separators, laminated separators, composite separators,coated laminated separators, coated composite separators, lithiumbattery separators, and/or methods of making such separators, and/ormethods of using such separators or batteries including such separators.In accordance with at least certain selected embodiments, the presentdisclosure or invention is directed to novel or improved lithium batteryseparators including a microporous membrane laminated to a coatednonwoven, and the coating may contain a polymer and optionally, a filleror particles, and/or to methods including the steps of: unwinding themicroporous membrane and the nonwoven, laminating the nonwoven andmicroporous membrane, and coating the nonwoven before or afterlamination.

At least selected embodiments, aspects or objects of the presentdisclosure or invention are directed to and/or may provide new, improvedor optimized separators, composites, batteries including same, and/orrelated methods, including, for example, a battery separator comprising:

-   -   a microporous membrane having a nonwoven laminated thereon,        and/or wherein said battery separator being a battery separator        for a lithium battery, wherein said battery separator being a        battery separator for a lithium ion battery, wherein said        battery separator being a battery separator for a lithium        secondary battery, and/or wherein said nonwoven being made        polymeric fibers, and the polymer being selected from the group        of: polyolefin, polyester, fluoro-polymer, e.g., PVDF, polyamide        (eg, nylon), polyaramid (KEVLAR, NOMEX), acrylic, PVC, or other        polymers, wherein said polyester being selected from the group        consisting of polyethylene terephthalate (PET), polybutylene        terephthalate (PBT), polyethylene naphthalate (PEN),        polytrimethylene terephthalate (PTT), co-polymers of the        foregoing, and blends of the foregoing, wherein said nonwoven        being made of bicomponent (hetero-fil) fibers, wherein said        bicomponent fiber being selected from the group consisting of        sheath-core fibers, side-by-side fibers, island-in-the-sea        fibers and combinations thereof, wherein said bicomponent fiber        having a low melt temperature component and a high melt        temperature component, where the low melt component having a        melt temperature less than the high melt temperature component,        wherein said low melt temperature component being a polyolefin,        wherein the polyolefin being selected from the group consisting        of: polyethylene (PE), polypropylene (PP), polymethylpetene        (PMP), polybutene (PB), co-polymers of the foregoing, and blends        of the foregoing, wherein said high melt temperature component        being selected from the group consisting of: polyester,        polyamide (eg, nylon), fluoro polymer (eg TEFLON), aramid (eg,        KEVLAR, NOMEX), liquid crystal polymer (VECTRAN),        polybenzimidazole (PBI), polybenzobisoxazole (PBO), wherein said        bicomponent fiber having a polyolefin sheath and a core being        made of a polymer selected from the group consisting of:        polyester, polyamide (eg, nylon), fluoro polymer (eg TEFLON),        aramid (KEVLAR, NOMEX), liquid crystal polymer (VECTRAN),        polybenzimidazole (PBI), polybenzobisoxazole (PBO), wherein said        bicomponent fiber having a polyethylene sheath and a core being        made of a polymer selected from the group consisting of:        polyester, polyamide (eg, nylon), fluoro polymer (eg TEFLON),        aramid (KEVLAR, NOMEX), liquid crystal polymer (VECTRAN),        polybenzimidazole (PBI), polybenzobisoxazole (PBO), wherein said        bicomponent fiber having a polyolefin sheath and a polyester        core, wherein said bicomponent fiber having a polyethylene        sheath and a polyethylene terephthalate (PET) core, wherein said        nonwoven being a carded nonwoven, a needle-punched nonwoven, an        air-laid nonwoven, a wet-laid nonwoven, a spunlaced        (hydroentangled) nonwoven, a spunbonded nonwoven, a melt-spun        nonwoven, an electro-spun nonwoven, and combinations thereof,        wherein said nonwoven being made of staple fibers, and/or        continuous filaments, wherein said nonwoven having a thickness        of less than 1 mil (25.4 microns), wherein said nonwoven having        a thickness of less than 0.5 mil (12.7 microns), wherein said        nonwoven having a thickness of less than 0.25 mil (6.4 microns),        and/or wherein said nonwoven further comprising a coating,        wherein said coating covering a fiber surface of the nonwoven,        wherein said coating partially or fully covering a fiber surface        of the nonwoven, wherein said coating covering a surface of the        nonwoven, wherein said coating partially covering a surface of        the nonwoven, wherein said coating fully impregnates into the        interior voids of the nonwoven, wherein said coating be made of        a ferroelectric polymer, wherein said ferroelectric polymer        being selected from the group consisting of polyethylene oxide        (PEO), polytetrafluoroethylene (PTFE), polyurethane (PU),        polyacrylonitrile (PAN), polymethylmethacrylate (PMMA),        polytetraethylene glycol diacrylate, polyvinylidene fluoride        (PVDF), co-polymers thereof, and blends containing the        foregoing, wherein said ferroelectric polymer being selected        from the group consisting of polyvinylidene fluoride (PVDF),        co-polymers thereof, and blends containing the foregoing,        wherein said polyvinylidene fluoride (PVDF) co-polymer being        selected from the group consisting of polyvinylidene        fluoride:hexafluoropropylene (PVDF:HFP) and polyvinylidene        fluoride:chlorotrifluoroethylene (PVDF:CTFE), wherein said        coating further including filler, wherein said filler being        blended into the coating before application to said nonwoven,        wherein said filler being added onto the coating after        application of the coating onto said nonwoven, wherein said        filler being an inert, thermally stable particle, wherein said        filler being a ceramic particle selected from the group        consisting of silicon dioxide (SiO₂), aluminum oxide (Al₂O₃),        calcium carbonate (CaCO₃), titanium dioxide (TiO₂), SiS₂, SiPO₄        and mixtures thereof, wherein said filler being a ceramic        particle selected from the group consisting of silicon dioxide        (SiO₂), aluminum oxide (Al₂O₃), calcium carbonate (CaCO₃),        titanium dioxide (TiO₂), and mixtures thereof, wherein said        filler being a ceramic particle selected from the group        consisting of silicon dioxide (SiO₂), aluminum oxide (Al₂O₃),        calcium carbonate (CaCO₃), and mixtures thereof, wherein said        filler having an average particle size in the range of 0.001        micron to 25 microns, most preferably in the range of 0.01        micron to 2 microns, wherein said filler having an average        particle size in the range of 0.01 micron to 2 microns, and/or        wherein said microporous membrane has a porosity in the range of        about 20-80%, wherein said microporous membrane has a porosity        in the range of about 28-60%, wherein said microporous membrane        has an average pore size in the range of about 0.02 to 2        microns, wherein said microporous membrane has an average pore        size in the range of about 0.08 to 0.5 micron, wherein said        microporous membrane has a Gurley Number in the range of about        15 to 150 sec, wherein said microporous membrane has a Gurley        Number in the range of about 30 to 80 sec, wherein said        microporous membrane has a single ply, wherein said single ply        being made of a polyolefin, wherein said polyolefin being        selected from the group consisting of: polyethylene (PE),        polypropylene (PP), polymethylpetene (PMP), polybutene (PB),        co-polymers of the foregoing, and blends of the foregoing,        wherein said polyolefin being selected from the group consisting        of: polyethylene (PE), polypropylene (PP), co-polymers of the        foregoing, and blends of the foregoing, wherein said polyolefin        being selected from the group consisting of: polyethylene (PE),        co-polymers of the foregoing, and blends of the foregoing,        wherein said polyolefin being polyethylene (PE), wherein said        microporous membrane has multiple plies, wherein said        microporous membrane has two plies, wherein each ply being made        of a different polymer, wherein one ply being made of a        polyolefin, wherein said polyolefin being selected from the        group consisting of: polyethylene (PE), polypropylene (PP),        polymethylpetene (PMP), polybutene (PB), co-polymers of the        foregoing, and blends of the foregoing, wherein said polyolefin        being selected from the group consisting of: polyethylene (PE),        co-polymers of the foregoing, and blends of the foregoing,        wherein said polyolefin being polyethylene (PE), wherein another        ply being made of a polyolefin, wherein said polyolefin being        selected from the group consisting of: polyethylene (PE),        polypropylene (PP), polymethylpetene (PMP), polybutene (PB),        co-polymers of the foregoing, and blends of the foregoing,        wherein said polyolefin being selected from the group consisting        of: polypropylene (PP), co-polymers of the foregoing, and blends        of the foregoing, wherein said polyolefin being polypropylene        (PP), wherein one ply being made of a polyethylene-based polymer        and another ply being made of a polypropylene-based polymer,        wherein said microporous membrane has three plies, wherein at        least two ply being made of a different polymer, wherein at        least two ply being made of a same polymer, wherein the outer        plies being made of the same polymer and the inner ply being        made of a different polymer, wherein the same polymer being a        polyolefin, wherein said polyolefin being selected from the        group consisting of: polyethylene (PE), polypropylene (PP),        polymethylpetene (PMP), polybutene (PB), co-polymers of the        foregoing, and blends of the foregoing, wherein said polyolefin        being selected from the group consisting of: polypropylene (PP),        co-polymers of the foregoing, and blends of the foregoing,        wherein said polyolefin being polypropylene (PP), wherein the        different polymer being a polyolefin, wherein said polyolefin        being selected from the group consisting of: polyethylene (PE),        polypropylene (PP), polymethylpetene (PMP), polybutene (PB),        co-polymers of the foregoing, and blends of the foregoing,        wherein said polyolefin being selected from the group consisting        of: polyethylene (PE), co-polymers of the foregoing, and blends        of the foregoing, wherein said polyolefin being polyethylene        (PE), and/or wherein said plies are layered as polypropylene        (PP)/polyethylene (PE)/polypropylene (PP); and/or a method of        making a laminated battery separator comprising the steps of:        unwinding a nonwoven, unwinding a microporous membrane, coating        the nonwoven with a coating material, and laminating the coated        nonwoven to the microporous membrane, and/or wherein the coating        material containing a ferroelectric material, wherein the        coating material containing a ferroelectric material and a        filler, and/or wherein coating being spraying, dipping, contact        coating, and/or brushing the coating material thereon; and/or a        method of making a laminated battery separator comprising the        steps of:    -   unwinding a nonwoven,    -   unwinding a microporous membrane,    -   laminating the nonwoven to the microporous membrane, and    -   coating the nonwoven with a coating material, and/or wherein the        coating material containing a ferroelectric material, wherein        the coating material containing a ferroelectric material and a        filler, and/or wherein coating being spraying, dipping, contact        coating, and/or brushing the coating material thereon; and/or a        battery separator, battery, and/or method as shown, disclosed        and/or described herein.

Battery separators and methods are disclosed. The battery separator maybe used in a lithium battery. The separator may include a microporousmembrane laminated to a coated nonwoven. The coating may contain apolymer and optionally, a filler or particles. The methods may includethe steps of: unwinding the microporous membrane and the nonwoven,laminating the nonwoven and microporous membrane, and coating thenonwoven before and/or after lamination.

The present invention may be embodied in other forms without departingfrom the spirit and the essential attributes thereof, and, accordingly,reference should be made to the appended claims, rather than to theforegoing specification, as indicated the scope of the invention.

We claim:
 1. A battery separator for a lithium battery comprising: Atleast one microporous membrane or layer, at least one nonwoven layer ormaterial on at least one side of said microporous membrane, saidnonwoven layer being bonded to or laminated on or to said microporousmembrane, and wherein at least one of: wherein at least one of saidseparator, said microporous membrane, and said nonwoven layer includingat least one of: at least one ferroelectric polymer, wherein saidferroelectric polymer being selected from the group consisting ofpolyethylene oxide (PEO), polytetrafluoroethylene (PTFE), polyurethane(PU), polyacrylonitrile (PAN), polymethylmethacrylate (PMMA),polytetraethylene glycol diacrylate, polyvinylidene fluoride (PVDF),co-polymers thereof, and blends containing the foregoing, wherein saidferroelectric polymer being selected from the group consisting ofpolyvinylidene fluoride (PVDF), co-polymers thereof, and blendscontaining the foregoing, wherein said polyvinylidene fluoride (PVDF)co-polymer being selected from the group consisting of polyvinylidenefluoride:hexafluoropropylene (PVDF:HFP) and polyvinylidenefluoride:chlorotrifluoroethylene (PVDF:CTFE), at least one filler,wherein said filler being an inert, thermally stable particle, whereinsaid filler being a ceramic particle selected from the group consistingof silicon dioxide (SiO₂), aluminum oxide (Al₂O₃), boehmite, calciumcarbonate (CaCO₃), titanium dioxide (TiO₂), SiS₂, SiPO₄, and mixtures,blends or combinations thereof, wherein said filler being a ceramicparticle selected from the group consisting of silicon dioxide (SiO₂),aluminum oxide (Al₂O₃), calcium carbonate (CaCO₃), titanium dioxide(TiO₂), and mixtures thereof, wherein said filler being a ceramicparticle selected from the group consisting of silicon dioxide (SiO₂),aluminum oxide (Al₂O₃), calcium carbonate (CaCO₃), and mixtures thereof,wherein said filler having an average particle size in the range of0.001 micron to 25 microns, most preferably in the range of 0.01 micronto 2 microns, wherein said filler having an average particle size in therange of 0.01 micron to 2 microns, a polymer or polymeric fibers,wherein said polymer or fibers being selected from the group of:polyolefin, polyester, fluoro-polymer, e.g., PVDF, polyamide (eg,nylon), polyaramid (KEVLAR, NOMEX), acrylic, PVC, co-polymers, blends,mixtures or combinations thereof, alone, or with other polymers, whereinsaid polyester being selected from the group consisting of polyethyleneterephthalate (PET), polybutylene terephthalate (PBT), polyethylenenaphthalate (PEN), polytrimethylene terephthalate (PTT), co-polymers,blends, mixtures or combinations of the foregoing, bicomponent(hetero-fil) fibers, wherein said bicomponent fiber being selected fromthe group consisting of sheath-core fibers, side-by-side fibers,island-in-the-sea fibers and combinations thereof, wherein saidbicomponent fiber having a low melt temperature component and a highmelt temperature component, where the low melt component having a melttemperature less than the high melt temperature component, wherein saidlow melt temperature component being a polyolefin, wherein thepolyolefin being selected from the group consisting of: polyethylene(PE), polypropylene (PP), polymethylpetene (PMP), polybutene (PB),co-polymers of the foregoing, and blends of the foregoing, wherein saidhigh melt temperature component being selected from the group consistingof: polyester, polyamide (eg, nylon), fluoro polymer (eg TEFLON), aramid(eg, KEVLAR, NOMEX), liquid crystal polymer (VECTRAN), polybenzimidazole(PBI), polybenzobisoxazole (PBO), wherein said bicomponent fiber havinga polyolefin sheath and a core being made of a polymer selected from thegroup consisting of: polyester, polyamide (eg, nylon), fluoro polymer(eg TEFLON), aramid (KEVLAR, NOMEX), liquid crystal polymer (VECTRAN),polybenzimidazole (PBI), polybenzobisoxazole (PBO), wherein saidbicomponent fiber having a polyethylene sheath and a core being made ofa polymer selected from the group consisting of: polyester, polyamide(eg, nylon), fluoro polymer (eg TEFLON), aramid (KEVLAR, NOMEX), liquidcrystal polymer (VECTRAN), polybenzimidazole (PBI), polybenzobisoxazole(PBO), wherein said bicomponent fiber having a polyolefin sheath and apolyester core, wherein said bicomponent fiber having a polyethylenesheath and a polyethylene terephthalate (PET) core, a carded nonwoven, aneedle-punched nonwoven, an air-laid nonwoven, a wet-laid nonwoven, aspunlaced (hydroentangled) nonwoven, a spunbonded nonwoven, a melt-spunnonwoven, an electro-spun nonwoven, and combinations thereof, staplefibers, and/or continuous filaments, wherein said nonwoven having athickness of less than 1 mil (25.4 microns), wherein said nonwovenhaving a thickness of less than 0.5 mil (12.7 microns), wherein saidnonwoven having a thickness of less than 0.25 mil (6.4 microns), whereinsaid nonwoven further comprising a coating, a coating wherein saidcoating covering a fiber surface of the nonwoven, wherein said coatingpartially or fully covering a fiber surface of the nonwoven, whereinsaid coating covering a surface of the nonwoven, wherein said coatingpartially covering a surface of the nonwoven, wherein said coating fullyimpregnates into the interior voids of the nonwoven, wherein saidcoating be made of a ferroelectric polymer, wherein said ferroelectricpolymer being selected from the group consisting of polyethylene oxide(PEO), polytetrafluoroethylene (PTFE), polyurethane (PU),polyacrylonitrile (PAN), polymethylmethacrylate (PMMA),polytetraethylene glycol diacrylate, polyvinylidene fluoride (PVDF),co-polymers thereof, and blends containing the foregoing, wherein saidferroelectric polymer being selected from the group consisting ofpolyvinylidene fluoride (PVDF), co-polymers thereof, and blendscontaining the foregoing, wherein said polyvinylidene fluoride (PVDF)co-polymer being selected from the group consisting of polyvinylidenefluoride:hexafluoropropylene (PVDF:HFP) and polyvinylidenefluoride:chlorotrifluoroethylene (PVDF:CTFE), wherein said coatingfurther including filler, wherein said filler being blended into thecoating before application to said nonwoven, wherein said filler beingadded onto the coating after application of the coating onto saidnonwoven, wherein said filler being an inert, thermally stable particle,wherein said filler being a ceramic particle selected from the groupconsisting of silicon dioxide (SiO₂), aluminum oxide (Al₂O₃), boehmite,calcium carbonate (CaCO₃), titanium dioxide (TiO₂), SiS₂, SiPO₄ andmixtures thereof, wherein said filler being a ceramic particle selectedfrom the group consisting of silicon dioxide (SiO₂), aluminum oxide(Al₂O₃), calcium carbonate (CaCO₃), titanium dioxide (TiO₂), andmixtures thereof, wherein said filler being a ceramic particle selectedfrom the group consisting of silicon dioxide (SiO₂), aluminum oxide(Al₂O₃), calcium carbonate (CaCO₃), and mixtures thereof, wherein saidfiller having an average particle size in the range of 0.001 micron to25 microns, most preferably in the range of 0.01 micron to 2 microns,wherein said filler having an average particle size in the range of 0.01micron to 2 microns, wherein said microporous membrane has a porosity inthe range of about 20-80%, wherein said microporous membrane has aporosity in the range of about 28-60%, wherein said microporous membranehas an average pore size in the range of about 0.02 to 2 microns,wherein said microporous membrane has an average pore size in the rangeof about 0.08 to 0.5 micron, wherein said microporous membrane has aGurley Number in the range of about 15 to 150 sec, wherein saidmicroporous membrane has a Gurley Number in the range of about 30 to 80sec, wherein said microporous membrane has a single ply, wherein saidsingle ply being made of a polyolefin, wherein said polyolefin beingselected from the group consisting of: polyethylene (PE), polypropylene(PP), polymethylpetene (PMP), polybutene (PB), co-polymers of theforegoing, and blends of the foregoing, wherein said polyolefin beingselected from the group consisting of: polyethylene (PE), polypropylene(PP), co-polymers of the foregoing, and blends of the foregoing, whereinsaid polyolefin being selected from the group consisting of:polyethylene (PE), co-polymers of the foregoing, and blends of theforegoing, wherein said polyolefin being polyethylene (PE), wherein saidmicroporous membrane has multiple plies, wherein said microporousmembrane has two plies, wherein each ply being made of a differentpolymer, wherein one ply being made of a polyolefin, wherein saidpolyolefin being selected from the group consisting of: polyethylene(PE), polypropylene (PP), polymethylpetene (PMP), polybutene (PB),co-polymers of the foregoing, and blends of the foregoing, wherein saidpolyolefin being selected from the group consisting of: polyethylene(PE), co-polymers of the foregoing, and blends of the foregoing, whereinsaid polyolefin being polyethylene (PE), wherein another ply being madeof a polyolefin, wherein said polyolefin being selected from the groupconsisting of: polyethylene (PE), polypropylene (PP), polymethylpetene(PMP), polybutene (PB), co-polymers of the foregoing, and blends of theforegoing, wherein said polyolefin being selected from the groupconsisting of: polypropylene (PP), co-polymers of the foregoing, andblends of the foregoing, wherein said polyolefin being polypropylene(PP), wherein one ply being made of a polyethylene-based polymer andanother ply being made of a polypropylene-based polymer, wherein saidmicroporous membrane has three plies, wherein at least two ply beingmade of a different polymer, wherein at least two ply being made of asame polymer, wherein the outer plies being made of the same polymer andthe inner ply being made of a different polymer, wherein the samepolymer being a polyolefin, wherein said polyolefin being selected fromthe group consisting of: polyethylene (PE), polypropylene (PP),polymethylpetene (PMP), polybutene (PB), co-polymers of the foregoing,and blends of the foregoing, wherein said polyolefin being selected fromthe group consisting of: polypropylene (PP), co-polymers of theforegoing, and blends of the foregoing, wherein said polyolefin beingpolypropylene (PP), wherein the different polymer being a polyolefin,wherein said polyolefin being selected from the group consisting of:polyethylene (PE), polypropylene (PP), polymethylpetene (PMP),polybutene (PB), co-polymers of the foregoing, and blends of theforegoing, wherein said polyolefin being selected from the groupconsisting of: polyethylene (PE), co-polymers of the foregoing, andblends of the foregoing, wherein said polyolefin being polyethylene(PE), and/or wherein said plies are layered as polypropylene(PP)/polyethylene (PE)/polypropylene (PP); wherein the separator is alaminated or composite separator with said nonwoven layer laminated tosaid microporous membrane before or after applying a coating to saidnonwoven layer, wherein said nonwoven being made polymeric fibers, andthe polymer being selected from the group of: polyolefin, polyester,fluoro-polymer, e.g., PVDF, polyamide (eg, nylon), polyaramid (KEVLAR,NOMEX), acrylic, PVC, or other polymers, wherein said polyester beingselected from the group consisting of polyethylene terephthalate (PET),polybutylene terephthalate (PBT), polyethylene naphthalate (PEN),polytrimethylene terephthalate (PTT), co-polymers of the foregoing, andblends of the foregoing, wherein said nonwoven being made of bicomponent(hetero-fil) fibers, wherein said bicomponent fiber being selected fromthe group consisting of sheath-core fibers, side-by-side fibers,island-in-the-sea fibers and combinations thereof, wherein saidbicomponent fiber having a low melt temperature component and a highmelt temperature component, where the low melt component having a melttemperature less than the high melt temperature component, wherein saidlow melt temperature component being a polyolefin, wherein thepolyolefin being selected from the group consisting of: polyethylene(PE), polypropylene (PP), polymethylpetene (PMP), polybutene (PB),co-polymers of the foregoing, and blends of the foregoing, wherein saidhigh melt temperature component being selected from the group consistingof: polyester, polyamide (eg, nylon), fluoro polymer (eg TEFLON), aramid(eg, KEVLAR, NOMEX), liquid crystal polymer (VECTRAN), polybenzimidazole(PBI), polybenzobisoxazole (PBO), wherein said bicomponent fiber havinga polyolefin sheath and a core being made of a polymer selected from thegroup consisting of: polyester, polyamide (eg, nylon), fluoro polymer(eg TEFLON), aramid (KEVLAR, NOMEX), liquid crystal polymer (VECTRAN),polybenzimidazole (PBI), polybenzobisoxazole (PBO), wherein saidbicomponent fiber having a polyethylene sheath and a core being made ofa polymer selected from the group consisting of: polyester, polyamide(eg, nylon), fluoro polymer (eg TEFLON), aramid (KEVLAR, NOMEX), liquidcrystal polymer (VECTRAN), polybenzimidazole (PBI), polybenzobisoxazole(PBO), wherein said bicomponent fiber having a polyolefin sheath and apolyester core, wherein said bicomponent fiber having a polyethylenesheath and a polyethylene terephthalate (PET) core, wherein saidnonwoven being a carded nonwoven, a needle-punched nonwoven, an air-laidnonwoven, a wet-laid nonwoven, a spunlaced (hydroentangled) nonwoven, aspunbonded nonwoven, a melt-spun nonwoven, an electro-spun nonwoven, andcombinations thereof, wherein said nonwoven being made of staple fibers,and/or continuous filaments, wherein said nonwoven having a thickness ofless than 1 mil (25.4 microns), wherein said nonwoven having a thicknessof less than 0.5 mil (12.7 microns), wherein said nonwoven having athickness of less than 0.25 mil (6.4 microns), wherein said nonwovenfurther comprising a coating, wherein said coating covering a fibersurface of the nonwoven, wherein said coating partially or fullycovering a fiber surface of the nonwoven, wherein said coating coveringa surface of the nonwoven, wherein said coating partially covering asurface of the nonwoven, wherein said coating fully impregnates into theinterior voids of the nonwoven, wherein said coating be made of aferroelectric polymer, wherein said ferroelectric polymer being selectedfrom the group consisting of polyethylene oxide (PEO),polytetrafluoroethylene (PTFE), polyurethane (PU), polyacrylonitrile(PAN), polymethylmethacrylate (PMMA), polytetraethylene glycoldiacrylate, polyvinylidene fluoride (PVDF), co-polymers thereof, andblends containing the foregoing, wherein said ferroelectric polymerbeing selected from the group consisting of polyvinylidene fluoride(PVDF), co-polymers thereof, and blends containing the foregoing,wherein said polyvinylidene fluoride (PVDF) co-polymer being selectedfrom the group consisting of polyvinylidene fluoride:hexafluoropropylene(PVDF:HFP) and polyvinylidene fluoride:chlorotrifluoroethylene(PVDF:CTFE), wherein said coating further including filler, wherein saidfiller being blended into the coating before application to saidnonwoven, wherein said filler being added onto the coating afterapplication of the coating onto said nonwoven, wherein said filler beingan inert, thermally stable particle, wherein said filler being a ceramicparticle selected from the group consisting of silicon dioxide (SiO₂),aluminum oxide (Al₂O₃), calcium carbonate (CaCO₃), titanium dioxide(TiO₂), SiS₂, SiPO₄ and mixtures thereof, wherein said filler being aceramic particle selected from the group consisting of silicon dioxide(SiO₂), aluminum oxide (Al₂O₃), calcium carbonate (CaCO₃), titaniumdioxide (TiO₂), and mixtures thereof, wherein said filler being aceramic particle selected from the group consisting of silicon dioxide(SiO₂), aluminum oxide (Al₂O₃), calcium carbonate (CaCO₃), and mixturesthereof, wherein said filler having an average particle size in therange of 0.001 micron to 25 microns, most preferably in the range of0.01 micron to 2 microns, wherein said filler having an average particlesize in the range of 0.01 micron to 2 microns, wherein said microporousmembrane has a porosity in the range of about 20-80%, wherein saidmicroporous membrane has a porosity in the range of about 28-60%,wherein said microporous membrane has an average pore size in the rangeof about 0.02 to 2 microns, wherein said microporous membrane has anaverage pore size in the range of about 0.08 to 0.5 micron, wherein saidmicroporous membrane has a Gurley Number in the range of about 15 to 150sec, wherein said microporous membrane has a Gurley Number in the rangeof about 30 to 80 sec, wherein said microporous membrane has a singleply, wherein said single ply being made of a polyolefin, wherein saidpolyolefin being selected from the group consisting of: polyethylene(PE), polypropylene (PP), polymethylpetene (PMP), polybutene (PB),co-polymers of the foregoing, and blends of the foregoing, wherein saidpolyolefin being selected from the group consisting of: polyethylene(PE), polypropylene (PP), co-polymers of the foregoing, and blends ofthe foregoing, wherein said polyolefin being selected from the groupconsisting of: polyethylene (PE), co-polymers of the foregoing, andblends of the foregoing, wherein said polyolefin being polyethylene(PE), wherein said microporous membrane has multiple plies, wherein saidmicroporous membrane has two plies, wherein each ply being made of adifferent polymer, wherein one ply being made of a polyolefin, whereinsaid polyolefin being selected from the group consisting of:polyethylene (PE), polypropylene (PP), polymethylpetene (PMP),polybutene (PB), co-polymers of the foregoing, and blends of theforegoing, wherein said polyolefin being selected from the groupconsisting of: polyethylene (PE), co-polymers of the foregoing, andblends of the foregoing, wherein said polyolefin being polyethylene(PE), wherein another ply being made of a polyolefin, wherein saidpolyolefin being selected from the group consisting of: polyethylene(PE), polypropylene (PP), polymethylpetene (PMP), polybutene (PB),co-polymers of the foregoing, and blends of the foregoing, wherein saidpolyolefin being selected from the group consisting of: polypropylene(PP), co-polymers of the foregoing, and blends of the foregoing, whereinsaid polyolefin being polypropylene (PP), wherein one ply being made ofa polyethylene-based polymer and another ply being made of apolypropylene-based polymer, wherein said microporous membrane has threeplies, wherein at least two ply being made of a different polymer,wherein at least two ply being made of a same polymer, wherein the outerplies being made of the same polymer and the inner ply being made of adifferent polymer, wherein the same polymer being a polyolefin, whereinsaid polyolefin being selected from the group consisting of:polyethylene (PE), polypropylene (PP), polymethylpetene (PMP),polybutene (PB), co-polymers of the foregoing, and blends of theforegoing, wherein said polyolefin being selected from the groupconsisting of: polypropylene (PP), co-polymers of the foregoing, andblends of the foregoing, wherein said polyolefin being polypropylene(PP), wherein the different polymer being a polyolefin, wherein saidpolyolefin being selected from the group consisting of: polyethylene(PE), polypropylene (PP), polymethylpetene (PMP), polybutene (PB),co-polymers of the foregoing, and blends of the foregoing, wherein saidpolyolefin being selected from the group consisting of: polyethylene(PE), co-polymers of the foregoing, and blends of the foregoing, whereinsaid polyolefin being polyethylene (PE), and/or wherein said plies arelayered as polypropylene (PP)/polyethylene (PE)/polypropylene (PP), andcombinations thereof.
 2. The battery separator of claim 1 wherein saidbattery separator being a battery separator for a secondary lithiumbattery, a lithium ion battery, or a lithium polymer battery.
 3. Thebattery separator of claim 1 wherein said nonwoven being made polymericfibers, and the polymer being selected from the group of: polyolefin,polyester, fluoro-polymer, e.g., PVDF, polyamide (eg, nylon), polyaramid(KEVLAR, NOMEX), acrylic, PVC, or other polymers.
 4. The batteryseparator of claim 3 wherein said polyester being selected from thegroup consisting of polyethylene terephthalate (PET), polybutyleneterephthalate (PBT), polyethylene naphthalate (PEN), polytrimethyleneterephthalate (PTT), co-polymers of the foregoing, and blends of theforegoing.
 5. The battery separator of claim 1 wherein said nonwovenbeing made of bicomponent (hetero-fil) fibers.
 6. The battery separatorof claim 5 wherein said bicomponent fiber being selected from the groupconsisting of sheath-core fibers, side-by-side fibers, island-in-the-seafibers and combinations thereof.
 7. The battery separator of claim 5wherein said bicomponent fiber having a low melt temperature componentand a high melt temperature component, where the low melt componenthaving a melt temperature less than the high melt temperature component.8. The battery separator of claim 7 wherein said low melt temperaturecomponent being selected from the group consisting of: a polyolefin,polyethylene (PE), polypropylene (PP), polymethylpetene (PMP),polybutene (PB), co-polymers of the foregoing, and blends of theforegoing, wherein said high melt temperature component being selectedfrom the group consisting of: polyester, polyamide (eg, nylon), fluoropolymer (eg TEFLON), aramid (eg, KEVLAR, NOMEX), liquid crystal polymer(VECTRAN), polybenzimidazole (PBI), polybenzobisoxazole (PBO), whereinsaid bicomponent fiber having a polyolefin sheath and a core being madeof a polymer selected from the group consisting of: polyester, polyamide(eg, nylon), fluoro polymer (eg TEFLON), aramid (KEVLAR, NOMEX), liquidcrystal polymer (VECTRAN), polybenzimidazole (PBI), polybenzobisoxazole(PBO), wherein said bicomponent fiber having a polyethylene sheath and acore being made of a polymer selected from the group consisting of:polyester, polyamide (eg, nylon), fluoro polymer (eg TEFLON), aramid(KEVLAR, NOMEX), liquid crystal polymer (VECTRAN), polybenzimidazole(PBI), polybenzobisoxazole (PBO), wherein said bicomponent fiber havinga polyolefin sheath and a polyester core, wherein said bicomponent fiberhaving a polyethylene sheath and a polyethylene terephthalate (PET)core, or combinations thereof.
 9. The battery separator of claim 1wherein said nonwoven being a carded nonwoven, a needle-punchednonwoven, an air-laid nonwoven, a wet-laid nonwoven, a spunlaced(hydroentangled) nonwoven, a spunbonded nonwoven, a melt-spun nonwoven,an electro-spun nonwoven, and combinations thereof, wherein saidnonwoven being made of staple fibers, and/or continuous filaments,wherein said nonwoven having a thickness of less than 1 mil (25.4microns), wherein said nonwoven having a thickness of less than 0.5 mil(12.7 microns), wherein said nonwoven having a thickness of less than0.25 mil (6.4 microns), or combinations thereof.
 10. The batteryseparator of claim 1 wherein said nonwoven further comprising a coating.11. The battery separator of claim 10 wherein said coating covering afiber surface of the nonwoven, wherein said coating partially or fullycovering a fiber surface of the nonwoven, wherein said coating coveringa surface of the nonwoven, wherein said coating partially covering asurface of the nonwoven, wherein said coating fully impregnates into theinterior voids of the nonwoven, or combinations thereof.
 12. The batteryseparator of claim 10 wherein said coating being made of a ferroelectricpolymer, wherein said ferroelectric polymer being selected from thegroup consisting of polyethylene oxide (PEO), polytetrafluoroethylene(PTFE), polyurethane (PU), polyacrylonitrile (PAN),polymethylmethacrylate (PMMA), polytetraethylene glycol diacrylate,polyvinylidene fluoride (PVDF), co-polymers thereof, and blendscontaining the foregoing, wherein said ferroelectric polymer beingselected from the group consisting of polyvinylidene fluoride (PVDF),co-polymers thereof, and blends containing the foregoing, wherein saidpolyvinylidene fluoride (PVDF) co-polymer being selected from the groupconsisting of polyvinylidene fluoride:hexafluoropropylene (PVDF:HFP) andpolyvinylidene fluoride:chlorotrifluoroethylene (PVDF:CTFE), orcombinations thereof.
 13. The battery separator of claim 10 wherein saidcoating further including filler, wherein said filler being blended intothe coating before application to said nonwoven, wherein said fillerbeing added onto the coating after application of the coating onto saidnonwoven, wherein said filler being an inert, thermally stable particle,wherein said filler being a ceramic particle selected from the groupconsisting of silicon dioxide (SiO₂), aluminum oxide (Al₂O₃), calciumcarbonate (CaCO₃), titanium dioxide (TiO₂), SiS₂, SiPO₄ and mixturesthereof, wherein said filler being a ceramic particle selected from thegroup consisting of silicon dioxide (SiO₂), aluminum oxide (Al₂O₃),calcium carbonate (CaCO₃), titanium dioxide (TiO₂), and mixturesthereof, wherein said filler being a ceramic particle selected from thegroup consisting of silicon dioxide (SiO₂), aluminum oxide (Al₂O₃),calcium carbonate (CaCO₃), and mixtures thereof, wherein said fillerhaving an average particle size in the range of 0.001 micron to 25microns, most preferably in the range of 0.01 micron to 2 microns,wherein said filler having an average particle size in the range of 0.01micron to 2 microns, or combinations thereof.
 14. The battery separatorof claim 1 wherein said microporous membrane has a porosity in the rangeof about 20-80%, wherein said microporous membrane has a porosity in therange of about 28-60%, wherein said microporous membrane has an averagepore size in the range of about 0.02 to 2 microns, wherein saidmicroporous membrane has an average pore size in the range of about 0.08to 0.5 micron, wherein said microporous membrane has a Gurley Number inthe range of about 15 to 150 sec, wherein said microporous membrane hasa Gurley Number in the range of about 30 to 80 sec, wherein saidmicroporous membrane has a single ply, wherein said single ply beingmade of a polyolefin, wherein said polyolefin being selected from thegroup consisting of: polyethylene (PE), polypropylene (PP),polymethylpetene (PMP), polybutene (PB), co-polymers of the foregoing,and blends of the foregoing, wherein said polyolefin being selected fromthe group consisting of: polyethylene (PE), polypropylene (PP),co-polymers of the foregoing, and blends of the foregoing, wherein saidpolyolefin being selected from the group consisting of: polyethylene(PE), co-polymers of the foregoing, and blends of the foregoing, whereinsaid polyolefin being polyethylene (PE), wherein said microporousmembrane has multiple plies, wherein said microporous membrane has twoplies, wherein each ply being made of a different polymer, wherein oneply being made of a polyolefin, wherein said polyolefin being selectedfrom the group consisting of: polyethylene (PE), polypropylene (PP),polymethylpetene (PMP), polybutene (PB), co-polymers of the foregoing,and blends of the foregoing, wherein said polyolefin being selected fromthe group consisting of: polyethylene (PE), co-polymers of theforegoing, and blends of the foregoing, wherein said polyolefin beingpolyethylene (PE), wherein another ply being made of a polyolefin,wherein said polyolefin being selected from the group consisting of:polyethylene (PE), polypropylene (PP), polymethylpetene (PMP),polybutene (PB), co-polymers of the foregoing, and blends of theforegoing, wherein said polyolefin being selected from the groupconsisting of: polypropylene (PP), co-polymers of the foregoing, andblends of the foregoing, wherein said polyolefin being polypropylene(PP), wherein one ply being made of a polyethylene-based polymer andanother ply being made of a polypropylene-based polymer, wherein saidmicroporous membrane has three plies, wherein at least two ply beingmade of a different polymer, wherein at least two ply being made of asame polymer, wherein the outer plies being made of the same polymer andthe inner ply being made of a different polymer, wherein the samepolymer being a polyolefin, wherein said polyolefin being selected fromthe group consisting of: polyethylene (PE), polypropylene (PP),polymethylpetene (PMP), polybutene (PB), co-polymers of the foregoing,and blends of the foregoing, wherein said polyolefin being selected fromthe group consisting of: polypropylene (PP), co-polymers of theforegoing, and blends of the foregoing, wherein said polyolefin beingpolypropylene (PP), wherein the different polymer being a polyolefin,wherein said polyolefin being selected from the group consisting of:polyethylene (PE), polypropylene (PP), polymethylpetene (PMP),polybutene (PB), co-polymers of the foregoing, and blends of theforegoing, wherein said polyolefin being selected from the groupconsisting of: polyethylene (PE), co-polymers of the foregoing, andblends of the foregoing, wherein said polyolefin being polyethylene(PE), wherein said plies are layered as polypropylene (PP)/polyethylene(PE)/polypropylene (PP), or combinations thereof.
 15. The batteryseparator of claim 1, wherein said separator is a composite or laminatebattery separator and is made by the steps of: unwinding a nonwoven,unwinding a microporous membrane, coating the nonwoven with a coatingmaterial, and laminating the coated nonwoven to the microporousmembrane; or, by the steps of: unwinding a nonwoven, unwinding amicroporous membrane, laminating the nonwoven to the microporousmembrane, and coating the nonwoven with a coating material; and, whereinthe coating material containing a ferroelectric material, wherein thecoating material containing a ferroelectric material and a filler, orcombinations thereof.
 16. In a battery, cell, pack, or module, theimprovement comprising the separator of claim
 1. 17. In a device,product, system, or vehicle, the improvement comprising the battery,cell, pack, or module of claim
 16. 18. A method of making a laminatedbattery separator comprising the steps of: unwinding a nonwoven,unwinding a microporous membrane, coating the nonwoven with a coatingmaterial, and laminating the coated nonwoven to the microporousmembrane.
 19. The method of claim 18 wherein the coating materialcontaining a ferroelectric material and an optional filler.
 20. Themethod of claim 18 wherein coating being spraying, dipping, contactcoating, and/or brushing the coating material thereon.
 21. A method ofmaking a laminated battery separator comprising the steps of: unwindinga nonwoven, unwinding a microporous membrane, laminating the nonwoven tothe microporous membrane, and coating the nonwoven with a coatingmaterial.
 22. The method of claim 21 wherein the coating materialcontaining a ferroelectric material and an optional filler.
 23. Themethod of claim 21 wherein coating being spraying, dipping, contactcoating, and/or brushing the coating material thereon.
 24. A batteryseparator, battery or method as shown, disclosed and/or describedherein.